I got my new set of 35 spline chrom-olly shafts for my Chevy dana 60 front end. I started on the long side and everything went together perfect. The shaft slid right in without any trouble. Thirty minutes later I had everything bolted back up on the driver side. I moved over to the short side and figured everything would go the same, but I couldn't be so lucky. The shaft does not want to slide in. I have tried everything. The ears on the axle shafts do not seem to fit through the knuckle. I can push it in and the shaft stops at the knuckle and the inner shaft I am still able to move around. I do not understand why just the passenger side shafts will not fit through the knuckle. Has anyone else run into this problem. After a couple hours of working with it I needed to quit before I went crazy and broke something. I really would like to keep from having to take off the knuckle if at all possible. I wouldn't think that I should have to remove the knuckle hopefully there will be something stupid I to try that I am not thinking of.

Well I just talked to a friend of mine and he told me he ran into the same thinng. He said that you need to grind the knuckle so the ears will fit through it. I tried grinding a little but when the shaft wouldn't fit but I figured I would get some more opinions before I got to far into it. I will be getting more into it tomorrow so I will let you know how it goes.

Don't grind the knuckle, grind or sand the shaft. Yukons and some aftermarket shafts have bigger yokes and need a little work to make them fit. I use a 6" sanding flap disc. Just test fit, sand, test fit, etc.. until they clear the hole. I have had about 6 shafts like this.

I had the same problem with 35spline yukon outers, they wouldnt go through the hole in the knuckle. Clearanced the knuckle little, didn't modify the shafts. I thought that the knuckle is plenty strong and didnt want to grind the shafts att all. Has held up ok.

Well I got up at 5 this morning to work on getting these shafts to fit before I headed to work. Yeah my wife thinks I am obsessed but who cares maybe I am. I chose to grind a little off of the knuckle and a little off the shaft. After removing very little material off of both the shafts slid right in. Wish I would have known this last night, there would have been a lot less cusing. Thanks for the info I really appreciate it.

Grinding at 5am? :homer:

:flipoff2:

Yeah and to add to it a touch of a hangover. You got to love the sound of a screeching grinder with a splitting head ache. I would call that dedication.